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<p>Brushless DC (BLDC) motors are commonly used in drones because of their compact design, low maintenance requirements, and high efficiency. They offer a high torque-to-weight ratio and accurate speed control, which is necessary for steady flights. Their lightweight design improves maneuverability and flight time and makes them more reliable. Traditional machining and lamination techniques limit the design flexibility of conventional BLDC motors rather than additive manufacturing. They have more weight than additive manufacturing. Their manufacturing limit’s part customization, optimization and integration, takes more time for production which lowers overall motor efficiency and drone flight performance. Additive manufacturing offers a more feasible solution to produce light weight, compact and efficient BLDC motor. This research is to design and analyze the Finite element analysis of BLDC motor in JMAG software. The focus of study is to manufacture the 3D printed stator of BLDC motor by 3wt%Fe–Si through selective laser melting (SLM). A comparative analysis is conducted to investigate the performance parameters of conventional and additive designs. A thrust set up was constructed to analyze the performance of AM motor with commercially available motor operated at 12&#xa0;V DC. After performing experimental analysis for both designs, the following parameters are obtained: AM design has achieved more torque than conventional design. Maximum thrust of 1.997N is obtained at 5942&#xa0;rpm by AM design. AM design has a greater efficiency of 72% while conventional design is 70% efficient.</p>

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Performance comparison of additively manufactured and conventional stators in permanent magnet brushless direct current motor

  • 期刊论文

  • 发表日期：

    2026年1月19日

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  • Amina Bibi,
  • Faisal Khan,
  • Ants Kallaste,
  • Shahid Hussain,
  • Muhammad Atif,
  • Hans Tiismus,
  • Toomas Vaimann

摘要

Brushless DC (BLDC) motors are commonly used in drones because of their compact design, low maintenance requirements, and high efficiency. They offer a high torque-to-weight ratio and accurate speed control, which is necessary for steady flights. Their lightweight design improves maneuverability and flight time and makes them more reliable. Traditional machining and lamination techniques limit the design flexibility of conventional BLDC motors rather than additive manufacturing. They have more weight than additive manufacturing. Their manufacturing limit’s part customization, optimization and integration, takes more time for production which lowers overall motor efficiency and drone flight performance. Additive manufacturing offers a more feasible solution to produce light weight, compact and efficient BLDC motor. This research is to design and analyze the Finite element analysis of BLDC motor in JMAG software. The focus of study is to manufacture the 3D printed stator of BLDC motor by 3wt%Fe–Si through selective laser melting (SLM). A comparative analysis is conducted to investigate the performance parameters of conventional and additive designs. A thrust set up was constructed to analyze the performance of AM motor with commercially available motor operated at 12 V DC. After performing experimental analysis for both designs, the following parameters are obtained: AM design has achieved more torque than conventional design. Maximum thrust of 1.997N is obtained at 5942 rpm by AM design. AM design has a greater efficiency of 72% while conventional design is 70% efficient.